{"id":141,"date":"2018-04-17T09:07:33","date_gmt":"2018-04-17T09:07:33","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=141"},"modified":"2026-11-06T15:57:09","modified_gmt":"2026-11-06T15:57:09","slug":"cable-coil-packing-machine-and-wire-packing-machine","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/cable-coil-packing-machine-and-wire-packing-machine\/","title":{"rendered":"Small-ID Horizontal Cable Coil Packing Machine: 90\u2013250 mm Core, Ring Clearance and Overlap"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong>\nOur horizontal cable coil packing machine wraps coils lying eye to sky, starting from a <strong>90 mm inner diameter<\/strong>. It handles wire and cable coils weighing 2\u201330 kg with an outer diameter (OD) of 150\u2013400 mm, achieving a cycle time of <strong>18\u201330 s per coil<\/strong>. Four synchronized electric centring arms align the coil precisely under the vertical wrapping ring, while an overhead pneumatic press-down roller secures the package during orbital rotation. Stored PLC recipes allow a single operator to execute rapid size changeovers without tooling adjustments.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" src=\"https:\/\/www.youtube.com\/embed\/NjYD4olOG7s?rel=0\" width=\"854\" height=\"480\" frameborder=\"0\" allowfullscreen=\"allowfullscreen\"><span data-mce-type=\"bookmark\" style=\"display: inline-block;width: 0px;overflow: hidden;line-height: 0\" class=\"mce_SELRES_start\"><\/span><\/iframe>\n<hr \/>\n<h2>Why a 90\u2013250 mm core is hard to wrap<\/h2>\n<p>In eye-through orbital packaging, the rotating ring, shuttle frame, and film roll must sweep through the open center of the coil on every cycle. While standard industrial coils present open eyes well above 300 mm, building wire (THHN\/THWN), data cables, and automotive wiring bundles are coiled with compact cores between 90 mm and 250 mm to save transit volume.<\/p>\n<p>Wrapping small cores exposes two physical bottlenecks:<\/p>\n<ol>\n<li><strong>Orbital clearance limitations:<\/strong> Standard orbital film carriages are too bulky to pass through an eye under 150 mm without colliding with the coil&#8217;s inner surface.<\/li>\n<li><strong>Radial overlap disparities:<\/strong> The surface speed of the wrapper varies dramatically across the workpiece geometry. An orbital wrapper tuned for the inner diameter will systematically under-wrap the outer circumference, causing packages to unravel during warehouse palletizing.<\/li>\n<\/ol>\n<p>The horizontal platform isolates the coil horizontally on driven rollers while driving a vertical ring through the open center, eliminating manual handling while solving mechanical clearance constraints.<\/p>\n<h2>How the horizontal ring works on a small coil<\/h2>\n<p>The machine supports the coil horizontally (eye to sky) on heavy-duty motorized rollers. A vertical aluminum ring traverses the core to apply stretch film, PVC tape, or protective paper along the radial axis.<\/p>\n<p>[ Overhead Pneumatic Press-Down Roller ]\n\u2502\n\u25bc\n\u250c\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500 Wrapping Ring \u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2510\n\u2502 \u2502 \u2502\n\u2502 \u250c\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500 Cable Coil (Eye to Sky) \u2500\u2500\u2500\u2500\u2500\u2500\u2510 \u2502\n\u2502 \u2502 [ 90\u2013250 mm Core ] \u2502 \u2502\n\u2502\u25c4\u2500\u2500\u2500\u253c\u2500 Film Roll \u2500\u2500\u2500\u2500\u2500\u2500\u2500\u25ba Inner Eye \u2502\u2500\u2500\u2500\u25ba\u2502\n\u2502 \u2514\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2518 \u2502\n\u2502 \u25b2 \u2502\n\u2514\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u253c\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2518\n\u2502\n[ Dual Motorized PU Support Rollers ]<\/p>\n<ol>\n<li><strong>Supporting rollers:<\/strong> Dual polyurethane (PU) coated rollers rotate the coil continuously about its central axis, protecting flexible cable jackets from surface scuffing.<\/li>\n<li><strong>Electric centring arms:<\/strong> Four synchronized radial arms clamp the coil symmetrically, positioning the exact geometric center along the ring centerplane.<\/li>\n<li><strong>Pneumatic press-down roller:<\/strong> An overhead clamp cylinder holds the coil securely against the cradle, counteracting rotational chatter on lightweight coils.<\/li>\n<li><strong>Orbital ring drive:<\/strong> Polyurethane friction drive wheels power the balanced orbital ring at speeds up to 120 r\/min.<\/li>\n<li><strong>Rotary encoder tracking:<\/strong> High-resolution optical encoders track roller rotation and ring position, regulating overlap pitch across the entire cycle.<\/li>\n<\/ol>\n<p>Automatic clamp-and-cut units grip and trim the wrapping material at the conclusion of each sequence without operator intervention.<\/p>\n<h2>FPCA100, FPCA-200, FPCA-300 side by side<\/h2>\n<p>Selecting the correct machine requires balancing core diameter (primary key) and coil weight (secondary key). The table below details our horizontal orbital range:<\/p>\n<table>\n<thead>\n<tr>\n<th>Parameter<\/th>\n<th>FPCA100<\/th>\n<th>FPCA-200<\/th>\n<th>FPCA-300<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Inner Diameter (ID)<\/td>\n<td>90\u2013250 mm<\/td>\n<td>150\u2013400 mm<\/td>\n<td>250\u2013510 mm<\/td>\n<\/tr>\n<tr>\n<td>Outer Diameter (OD)<\/td>\n<td>150\u2013400 mm<\/td>\n<td>250\u2013500 mm<\/td>\n<td>400\u2013900 mm<\/td>\n<\/tr>\n<tr>\n<td>Coil Width \/ Height<\/td>\n<td>50\u2013180 mm<\/td>\n<td>80\u2013200 mm<\/td>\n<td>60\u2013300 mm<\/td>\n<\/tr>\n<tr>\n<td>Coil Weight Capacity<\/td>\n<td>2\u201330 kg<\/td>\n<td>2\u201350 kg<\/td>\n<td>20\u2013200 kg<\/td>\n<\/tr>\n<tr>\n<td>Ring Rotation Speed<\/td>\n<td>10\u2013120 r\/min<\/td>\n<td>10\u2013120 r\/min<\/td>\n<td>10\u201390 r\/min<\/td>\n<\/tr>\n<tr>\n<td>Packaging Cycle Time<\/td>\n<td>18\u201330 s\/pcs<\/td>\n<td>20\u201330 s\/pcs<\/td>\n<td>20\u201338 s\/pcs<\/td>\n<\/tr>\n<tr>\n<td>Overlap Ratio Range<\/td>\n<td>20\u201390%<\/td>\n<td>20\u201380%<\/td>\n<td>10\u201390%<\/td>\n<\/tr>\n<tr>\n<td>Installed Power<\/td>\n<td>1.8 kW<\/td>\n<td>2.0 kW<\/td>\n<td>2.4 kW<\/td>\n<\/tr>\n<tr>\n<td>Electrical Supply<\/td>\n<td>AC 380 V, 60 Hz<\/td>\n<td>AC 380 V, 50 Hz<\/td>\n<td>AC 380 V, 60 Hz<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><strong>Handling out-of-boundary specifications:<\/strong>\nIf a coil has an ID of 200 mm but weighs 60 kg, it falls within the geometric envelope of the FPCA-200 (ID 150\u2013400 mm), but exceeds its 2\u201350 kg weight rating. In this scenario, running the package on a standard FPCA-200 risks premature drive-roller fatigue and motor overload. The application requires upgrading to an FPCA-300 chassis with custom lowered support rollers, or reinforcing the FPCA-200 roller bearings alongside a lower drive rotation speed.<\/p>\n<h2>Ring clearance and film roll diameter<\/h2>\n<p>For an orbital ring to wrap an eye-to-sky coil, the film roll and dispensing shuttle must pass freely through the inner eye. This imposes a strict mechanical boundary:<\/p>\n<p><code>OD_film + Carriage_Profile &lt; Coil_ID<\/code><\/p>\n<p>Simultaneously, the internal ring clear diameter must accommodate the coil wall thickness, vertical carriage stroke, and runout:<\/p>\n<p><code>Ring_ID_clear &ge; (Coil_OD - Coil_ID) \/ 2 + Carriage_Envelope + Safety_Margin<\/code><\/p>\n<p>When wrapping a compact 90 mm core on the FPCA100:<\/p>\n<ul>\n<li>The film roll outside diameter must stay below <code>ID_coil &minus; 2 &times; wall clearance<\/code>, so the roll passes the bore without touching the coil wall; check it against the roll you buy.<\/li>\n<li>The standard film carriage utilizes a cantilevered, low-profile mandrel designed for narrow stretch tape (50 mm width).<\/li>\n<li><strong>Alternative for thick films:<\/strong> If handling heavy puncture-resistant film on cores under 100 mm, we utilize coreless pre-stretched film rolls or a high-ratio external pre-stretch unit, reducing the film roll core bulk while maintaining tensile strength.<\/li>\n<\/ul>\n<h2>Overlap at the OD: the ratio effect<\/h2>\n<p>A common packaging defect occurs when film appears tight in the center but loose and separated at the outer perimeter. Because the coil turns at a fixed angular velocity while the ring orbits at constant speed, the linear advance rate across the surface is proportional to diameter:<\/p>\n<p><code>Linear Advance_OD = Advance_ID &times; (OD \/ ID)<\/code><\/p>\n<p>Consequently, the effective overlap percentage at the outer perimeter drops relative to the inner core by the direct ratio of <code>OD \/ ID<\/code>:<\/p>\n<p><code>Outer Overlap % &asymp; 100% - [(100% - Inner Overlap %) &times; (OD \/ ID)]<\/code><\/p>\n<h3>Example A: Compact Wire Coil (FPCA100)<\/h3>\n<ul>\n<li><strong>Dimensions:<\/strong> ID 90 mm, OD 150 mm (OD\/ID ratio = 1.67).<\/li>\n<li>If the HMI is programmed for a target 50% overlap at the outer diameter (OD 150 mm), the inner core (ID 90 mm) receives an effective overlap exceeding 70%. The inner core builds up multiple overlapping plies, providing rigid structural containment at the center.<\/li>\n<\/ul>\n<h3>Example B: Expanded Coil Profile (FPCA100 Upper Limit)<\/h3>\n<ul>\n<li><strong>Dimensions:<\/strong> ID 250 mm, OD 400 mm (OD\/ID ratio = 1.60).<\/li>\n<li>At 400 mm OD, the perimeter measures <code>3.1416 &times; 400 mm = 1,257 mm<\/code>. At an inner eye advance of 15 mm per revolution, outer perimeter advance reaches <code>15 mm &times; 1.60 = 24 mm<\/code>. The film roll width must be sized to at least 60 mm to maintain a stable 60% outer perimeter overlap without protective gaps.<\/li>\n<\/ul>\n<h2>Cycle time and ring speed<\/h2>\n<p>Cycle duration is determined by ring rotation speed, coil drive speed, and programmed film layer overlap. <\/p>\n<p>On the FPCA100, the ring operates from 10 to 120 r\/min via variable frequency drive (VFD). At top operational velocity (120 r\/min = 2 revolutions per second):<\/p>\n<ul>\n<li>An average 20-second active sequence delivers 35 to 40 complete ring rotations, including acceleration and deceleration ramping.<\/li>\n<li>A 200 mm OD coil at 60% overlap runs inside the published 18\u201330 s\/pcs window for the FPCA100.<\/li>\n<li>Larger coils (e.g., 400 mm OD on the FPCA100, or coils running on the FPCA-200 \/ FPCA-300 platforms) require additional rotation cycles to ensure multi-layer protective coverage, resulting in cycle times between 20 and 38 seconds.<\/li>\n<\/ul>\n<h2>Guarding, film and controls<\/h2>\n<p>The horizontal wrapping platform accommodates a wide selection of packaging media:<\/p>\n<ul>\n<li><strong>LLDPE stretch film:<\/strong> 50\u2013100 mm roll width, gauge as ordered. Provides dust sealing, moisture protection, and tension retention.<\/li>\n<li><strong>PVC \/ PE Stretch Tape:<\/strong> Delivers high puncture resistance and rigid bundle stabilization.<\/li>\n<li><strong>Woven Polypropylene (PP) \/ Crepe Paper:<\/strong> Used for mechanical transit protection during export shipping.<\/li>\n<\/ul>\n<p><strong>Safety and Electrical Systems:<\/strong><\/p>\n<ul>\n<li>Integrated perimeter safety guards shield the rotating ring assembly. <\/li>\n<li>Electrical designs comply with CE Low Voltage and Machinery Directives, risk assessment follows <strong>ISO 12100:2010<\/strong>, and mechanical safety conforms to <strong>EN 415-10:2014<\/strong>.<\/li>\n<li>Drive controls utilize or PLCs with HMI touchscreens. Closed-loop optical encoders monitor ring-roller synchronization, triggering instant emergency braking if film snaps or mechanical resistance spikes.<\/li>\n<\/ul>\n<h2>Selection checklist<\/h2>\n<p>Audit the following specifications prior to equipment selection:<\/p>\n<ol>\n<li><strong>Core ID Check:<\/strong> Measure minimum core ID. If between 90 mm and 150 mm, select FPCA100; if between 150 mm and 250 mm, compare package weight.<\/li>\n<li><strong>Coil Weight vs. Frame:<\/strong> Match maximum bundle weight against capacity (FPCA100: 2\u201330 kg; FPCA-200: 2\u201350 kg; FPCA-300: 20\u2013200 kg).<\/li>\n<li><strong>Film Roll Profile:<\/strong> Ensure film roll outer diameter does not exceed <code>Coil_ID - 15 mm<\/code>.<\/li>\n<li><strong>Line Integration:<\/strong> Determine if coils will be hand-loaded or transferred automatically via upstream inline coilers.<\/li>\n<li><strong>Utility Verification:<\/strong> Confirm floor utilities meet 0.5\u20130.7 MPa pneumatic pressure and AC 380 V industrial power.<\/li>\n<\/ol>\n<h2>Engineering FAQ<\/h2>\n<p><strong>What is the smallest coil inner diameter the FPCA100 can wrap?<\/strong>\nThe physical limit is 90 mm ID. The machine wraps from 90 mm up to 250 mm ID using a low-profile film carriage that navigates tight inner clearances without core contact.<\/p>\n<p><strong>How does the machine prevent light coils (2\u20135 kg) from jumping during wrapping?<\/strong>\nAn overhead, soft-polyurethane pneumatic press-down roller extends onto the top of the coil prior to ring acceleration, clamping the package securely against the driven base rollers.<\/p>\n<p><strong>How do we resolve the difference between inner and outer film overlap?<\/strong>\nBecause outer linear speed is higher by a factor of (OD\/ID), PLC recipes calculate ring and roller speeds based entirely on the target outer overlap. Setting an outer overlap of 30% to 50% ensures the inner core receives a dense, protective multi-ply seal.<\/p>\n<p><strong>Which machine handles coils exceeding 400 mm OD?<\/strong>\nCoils exceeding 400 mm OD transition to our larger horizontal wrapping systems:<\/p>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Cable-packing-machine\/Cable-Coil-Wrapping-Machine-FPCA-200.html\">FPCA-200 Cable Coil Wrapping Machine<\/a>: OD 250\u2013500 mm, weight capacity 2\u201350 kg.<\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Cable-packing-machine\/Cable-coil-wrapping-machine-FPCA-300.html\">FPCA-300 Heavy-Duty Cable Coil Wrapping Machine<\/a>: OD 400\u2013900 mm, weight capacity 20\u2013200 kg.<\/li>\n<\/ul>\n<h2>Next step<\/h2>\n<p>To validate your cable package dimensions and obtain layout simulations:<\/p>\n<ol>\n<li><strong>Send Coil Dimensions:<\/strong> Submit your min\/max core ID, OD, height, package weights, and target throughput to our engineering team.<\/li>\n<li><strong>Review Layout within 24\u201348 Hours:<\/strong> Our design engineers will generate an equipment layout drawing, overlap schedule, and cycle-time estimate.<\/li>\n<li><strong>Line Integration Consultation:<\/strong> Coordinate with our automation engineering desk to align conveyor transfer heights and coiler PLC handshake protocols.<\/li>\n<\/ol>\n<p>Explore our dedicated machinery specifications:<\/p>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Cable-packing-machine\/Cable-Coil-Packing-Machine-FPCA100.html\">FPCA100 Horizontal Cable Coil Packing Machine<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Cable-packing-machine\/Cable-Coil-Wrapping-Machine-FPCA-200.html\">FPCA-200 Cable Coil Wrapping Machine<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Cable-packing-machine\/Cable-coil-wrapping-machine-FPCA-300.html\">FPCA-300 Heavy-Duty Cable Coil Wrapping Machine<\/a><\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-11-05<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive summary Our horizontal cable coil packing machine wraps coils lying eye to sky, starting from a 90 mm inner diameter. It handles wire and cable coils weighing 2\u201330 kg with an outer diameter (OD) [&hellip;]<\/p>","protected":false},"author":1,"featured_media":2335,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Small-ID Cable Coil Wrapping Machine: 90 mm ID Coils","_seopress_titles_desc":"How our horizontal cable coil wrapper packs small coils from 90 mm ID: ring passing the eye, centring arms, press-down device, 18\u201330 s 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